production methods mass production. industrial practices industrial practices are designed to ensure...

Production methodsMass production

Industrial practices

Industrial practices are designed to ensure that quality products are manufactured efficiently at a profit. They involve designers working together with clients and manufacturers, all of whom need to keep the needs of the consumer in mind.

Roles in industrial practiceThe client

The client identifies the need for a product through market research and uses this to provide a design brief for the designer. They set production deadlines and the price of the product. The client is usually a manufacturer or retailer.

The designer works to the design brief and researches market trends, fabrics and processes, taking into account any relevant societal, cultural, moral, environmental or safety issues. They produce a design specification, product costings, and help plan manufacturing.

The designer

The manufacturer

The manufacturer uses models or prototypes made by the designer, and works out the most efficient way of manufacturing the product. They produce a production plan and a work schedule. During manufacture they aim to keep material and labour costs down, while producing a high-quality, safe product on schedule in a safe environment.

The user or consumer

The user or consumer demands a product that meets their requirements: a high-quality, value-for-money and safe product

Mass production ( flow production)

Manufacture of large quantities of products

Low production costsAll finished products are the sameProduction line workers only do repetitive

tasks

Mass production began in Detroit in 1914 when Henry Ford discovered that a moving assembly line using interchangeable parts could radically reduce the cost of making motor cars. He sold 18m Model T Fords, transforming America into the first car-owning democracy, at a price that dropped from $600 to $250 over 15 years.

Mass production was unpleasant work, with high turnover. To retain his unskilled workforce, Ford doubled their wages to $5 per day - justified by higher productivity.

Mass productionMass production of textiles products in a factoryMass production is the industrial-scale

manufacture of large quantities of products, usually on a production line. Standardised production methods mean it is suitable for products that rarely need to be redesigned. Mass production is used for products that are needed in very large numbers, eg socks or jeans. Often, products are made overseas where labour costs are lower.

Automated mass productiopn

One off production

One-off productionIn one-off production a single product is

designed and made to a client's specification. Labour and material costs are high, and a high level of design and manufacturing skills are needed. An example of one-off production would be a made-to-measure wedding dress.

Batch production

Batch productionIn batch production set quantities of a

product are manufactured to order. Batch production requires a high level of design, pattern making and sampling skills. Materials are cost-effective and manufacturing costs are lower than one-off production

Just-in-time manufacturing is when materials are

ordered so they arrive just as they are needed.

Cell productionCell production has the flow production line

split into a number of self-contained units. Each team or ‘cell’ is responsible for a significant part of the finished article and, rather than each person only carrying out only one very specific task, team members are skilled at a number of roles, so it provides a means for job rotation and team working

Preparation stage: the amount of materials to buy-in. Preparation of garment patterns, templates and lay plans.

Processing stage: fabric spreading, cutting, labelling and bundling of fabric pieces.

Assembly stage: instructions for fusing, joining and pressing the separate parts.

Finishing stage: instructions for decorative/functional finishing and final pressing.

Packaging stage: how to label, hang, fold and cover the product ready for transport.

Systems in textile production

Systems and subsystems In a production system, a number of different processes

or subsystems take place at the same time. Examples of subsystemsLay-planning: this involves laying out pattern pieces of

a fabric to work out the quantity and cost of material.Costing: this involves estimating how much each

product costs to make, including materials, labour, rent and energy costs.

Quality control: this involves the checks for quality that take place at all stages.

Elementary flow chart symbols

Simple flow chart for cruise control in a motor vehicle